Pulling my hair out

So, thought I had rear main seal out, but apparently I don't.
Cap is off, I can take an 1/8" brass punch (about like coat hanger but thicker) and band that all the way around crank and back out other side of cap. I can DOUBLE UP on brass punch, and get that around crank and back out other side of crank, but if I try to slide in new gasket...NO BUENO!!
It hits something exactly half way like a wall.
Before you answer, I am very mechanically inclined, yes the gasket is lubed, yes I've done this job before many times on small block Chevy. I know you have to follow the curve, keep the gasket against crank, but this is weird. It just STOPS. Yet when I put punches thru or anything else I get no rope gasket material. I can even hear the metal against the punch. I've blown it out with air, etc etc. when I double up the punch, meaning use two pieces at same time it fills space completely and they both come out other side of cap clean.
I am lost. Can't afford nor do I have the time to pull motor. Although at this rate...
I've been on rear main for a week now (in spare time)
Am I missing something?
Is jeep haunted?

 

Try pulling the new seal instead of pushing it.

http://cdn1.bigcommerce.com/server4.../27000__06357__00962.1360953669.1280.1280.JPG

 

It's not a rope seal, it's the new style rubber seal.

 

Try turning the crankshaft while feeding the seal in? Maybe it's hitting an oil feed hole.

 

Excellent idea!
i did that also, still gets stuck in same place. I'm gonna do that again tomorrow and rotate crank until oil feed is on bottom and I can see it. So weird. Slides in like butter...half way either direction.
is there a oil feed in bearing cap that sits in block???

 

I had the very same same thought, but the oil pressure feed would be to the bearing shell and journal. Is there a hole in the seal channel location?

 

Not sure I understand Pete.
There is a feed hole in crank which I can turn over, not sure if there is a feed hole in the upper half of bearing that snaps into the block.

 

Me either. Not familiar with that engine. Just shooting in the dark.

 

How was the old seal installed when you pulled the cap off??

Did you have any issues getting the old seal out?

 

Keep in mind motor is in jeep, so I am under jeep and just pulled rear cap. Old seal was original "rope" style. New seal is improved rubber 2 piece design.
Getting top half of old rope seal out was a burden, to put it nicely.
Basically pushed pulled and used a drywall screw and dykes to pull it out. Took forever along with emotional support from others here on this website.
Now the new rubber only slides in half way, then hits a wall, yet I can push wire and other things all the way thru. Crazy.

 

Did you notice any scuff marks in the old rope seal-----outer surface of the top half??

 

You sure you got all the old seal out? Can you thread a piece of parachute cord (for example) through the seal groove?

Are the other main caps still loose? You might try hanging from the crank to get a few extra thousandths of space in the seal groove.

 

No scuff marks, but hard to tell, I disinigrated old seal when removing. I agree, if anything, has to be a stubborn blob of old seal in there. I'm at my wits end.
Keep the ideas coming!

 

The Sneaky Pete might be able to drag a chunk of old seal out of there.

 

Might be a good time to check all the main bearings. You could try loosening all the mains to create more space for the new seal.